Hot lamination process for the manufacture of a combination contact/contactless smart card

ABSTRACT

A plastic smart card, such as a card having a radio frequency identification (RFID) proximity function, including at least one electronic element embedded therein and a physical contact card function and the hot lamination process for the manufacture of this dual function smart card and other plastic cards including a micro-chip embedded therein. The process results in a card having a preferred overall thickness in the range of 0.028 inches to 0.032 inches with a surface suitable for receiving dye sublimation printing—the variation in card thickness across the surface should not exceed 0.0005 inches. A card manufactured in accordance with the present invention also complies with all industry standards and specifications. Also, the hot lamination process of the present invention results in an aesthetically pleasing card. The invention also relates to a plastic card formed in accordance with the hot lamination process of the present invention.

This application is a continuation of application 08/918,582, filed Aug.19, 1997, now U.S. Pat. No. 6,036,099, which claimed the benefit ofprovisional application Ser. No. 60/024,255, filed Aug. 21, 1996; acontinuation-in-part of application Ser. No. 08/727,789 filed Oct. 7,1996, now U.S. Pat. No. 5,817,207, which claimed the benefit ofprovisional application Ser. No. 60/005,685, filed on Oct. 17, 1995.

FIELD OF THE INVENTION

The present invention relates generally to plastic cards and themanufacture thereof by a hot lamination process, and more particularlyto smart cards and the manufacture of these such that they conform toindustry size and performance standards and conventions and that have asuperior outer surface as compared to known smart cards such that thecard may receive dye sublimation printing or the like. Even morespecifically, the preferred embodiments of the present invention relateto dual function cards containing imbedded electronic elements as wellas an exposed electronic contact surface.

BACKGROUND OF THE INVENTION

As the use of plastic cards for credit cards, automated teller machine(ATM) cards, identification cards, and like continues to become morewidespread, the problems associated with the use of such cardscorrespondingly increase. Credit card fraud and identification cardfraud are becoming larger problems everyday, and this fraud hasintroduced uncertainties into our systems of commerce and our securitysystems. Using easily available technology, criminals are able tomanufacture credit/debit cards, ATM cards, identification cards, and thelike having another's account code, identification code, or otherpersonal information embedded in the magnetic stripe thereof. Thus, forexample, criminals may steal hundreds or thousands of legitimate creditcard account numbers and manufacture many additional cards bearing thestolen information. These fraudulent cards are then usable by thecriminals to purchase goods and to receive cash with the legitimate cardholder and the card issuer left holding the bill.

Likewise, so called debit cards are becoming increasingly popular. Thesecards have stored thereon a certain amount of value for which the cardowner has previously paid. For example, a subway rider may purchase acard good for X fares, with one fare being deducted from the card eachtime the owner rides the subway. Criminals have also been able tomanipulate the data stored on these cards to defraud the merchants andothers.

The ease in which criminals have been able to manufacture and ormanipulate known cards results from the existence of the easily alteredmagnetic stripe storage medium used by known cards. These magneticstripes are easily programmed and reprogrammed using commonly availabletechnology. Thus, there has been found a need in the plastic cardindustry to provide a more secure plastic card that is very difficult orimpossible to fraudulently manipulate.

The likely successor to magnetic stripe cards is known as a memory orsmart card. A smart card can generally be described as a card having anintegrated circuit with memory that is capable of making decisions. Thecategory of smart cards can be further divided into subcategories basedon the type of memory or type of communication with an associated cardreader. Types of smart cards include contact cards (cards requiringphysical touch between the terminal reader and the surface of the card)and contactless cards (cards which interact with the terminal readerusing an electromagnetic coupling). Contactless cards may also bereferred to as “proximity” cards. This technology may serve as asubstitute for or be provided as an addition to the magnetic stripe on acard.

One specific type of smart card is a dual function contact/contactlessmicroprocessor chip plastic card commonly referred to in the industry asa dual function card. This card utilizes a single microprocessor tocontrol both physical contact and proximity features of the card.

While these smart cards have been found to have infinitely morecapability than magnetic stripe cards as well as being more successfulin preventing or limiting fraud, they are more difficult and expensiveto manufacture relative to ordinary magnetic stripe cards. One of thebiggest obstacles to the wide spread manufacture and use of smart cardshas been the inability of card manufacturers to manufacturer a smartcard that meets all industry standards and specifications, such as thoseset by the International Standards Organization (ISO), that aresufficiently aesthetically pleasing (wherein the embedded electronicsare hidden from view), and that have a sufficiently regular or flatsurface such that one or both surfaces of the card may be printed onusing the very popular and widespread dye sublimation technology.

Limitations to known plastic cards with embedded computer chips andelectronics are that they a) are too thick to work in connection withexisting card reading machinery (ATM machines, telephones), b) have asurface that is too irregular to properly and consistently receive dyesublimation printing, c) utilize manufacturing processes making thecards cost prohibitive. Moreover, prior attempts to manufacture asufficiently thin plastic card including a computer chip embeddedtherein have resulted in a card with inferior aesthetic qualities suchas the ability to see the embedded computer chip through the plastic.

Furthermore, due to the presence of both internal and surfaceelectronics within the card, the manufacture of a dual function cardpresents its own unique set of obstacles and problems, different fromthe manufacture of cards with fully embedded electronics.

SUMMARY OF THE INVENTION

The present invention is therefore directed to a hot lamination methodfor the manufacture of a plastic card having at least one electronicelement embedded therein as well as at least one electronic element withan exposed contact surface and to such plastic cards. The card has anoverall thickness in the range of 0.028 inches to 0.032 inches andcomprises a plastic core having at least one electronic element embeddedtherein with at least one of the upper and lower surfaces of the corecomprising a coating printed or otherwise applied thereon. A portion ofthe card's outer surface exposes a contact surface electronic elementoperatively connected to the card's internal electronics. Anoverlaminate film is preferably provided over the coated surface of thecore and the resulting card has a variation in thickness across thesurfaces thereof of no greater than approximately 0.0005 inches.

The hot lamination method of the present invention comprises the stepsof providing upper (first) and lower (second) plastic core sheets,positioning at least one electronic element between the first and secondcore sheets to thus form a core, and placing the core in a laminator andclosing the laminator with minimal or no laminator ram pressure appliedto the core. A heat cycle is applied to the core sheets in the laminatorto cause complete or partial flow of the plastic sheets. The laminatorram pressure is then increased in combination with the heat. A coolingcycle is then applied to the core in the laminator, preferably with anassociated increase in ram pressure, and the core is removed from thelaminator.

In the preferred embodiment, the laminated core next undergoes acontrolled depth milling operation to expose one or more contact padswhich comprise part of the internal, embedded electronic element.

In alternative embodiments, one of the plastic sheets contained apre-formed window which is positioned over the contact pads, prior tolamination. A spacer, integral to the corresponding platen or separatetherefrom, is utilized to prevent or limit the flow of plastic into thewindow region so as not to coat the contact pads with plastic during thecard manufacturing process.

At least one surface of the core is then printed on using a printingpress or similar printing apparatus, a sheet of overlaminate film isplaced on at least one side of the core, and the core is once againplaced in a laminator. A heat cycle is applied to the core with itsoverlaminate film, and a cooling cycle is thereafter applied, resultingin a sheet of plastic card stock from which one or more cards may becut.

Contact surface elements are installed into the window region of aplastic card and in operable contact with contact pads.

The invention is also directed to a card manufactured in accordance withthe above process which results in a plastic card having a thickness inthe range of approximately 0.028 inches to 0.032 inches with a surfacesmoothness of at least approximately 0.0005 inches as is required byInternational Standards Organization (ISO) and American NationalStandards Institute (ANSI) standards.

The present invention provides numerous advantages over known plasticcards and known plastic card manufacturing processes, and includes theformation of a plastic card with electronic elements such as a computerchip embedded therein with a pleasing aesthetic appearance, having asufficiently smooth and regular surface such that the card may receivedye sublimation printing, and possessing sufficient durability andcharacteristics to comply with all industry specifications andstandards.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a plastic card in accordance with thepresent invention;

FIG. 2 is a perspective view of the card shown in FIG. 1, illustratingthe embedded and exposed electronics incorporated into the card;

FIG. 2A is a side elevational view of the card core illustrating variouselectronic elements that may be embedded in a card in accordance withthe present invention;

FIG. 3A is a cross sectional view of the card illustrated in FIG. 2,taken through section line 3A—3A.

FIG. 3B is a cross sectional view of the card illustrated in FIG. 2,taken through section line 3B—3B.

FIG. 4 is a perspective view of a plurality of electronic elementspositioned on a sheet of plastic core stock and covered by a secondsheet of plastic core stock.

FIG. 5 is a schematic cross sectional view illustrating a bookcomprising the core, containing electronics, as positioned in alaminator;

FIG. 5A is an enlarged cross-sectional view of the portion encircled inFIG. 5 for an alternative embodiment, utilizing a spacer, for producinga card according to the present invention;

FIG. 6 schematically illustrates the process of printing on the core;

FIG. 7 is a schematic cross sectional view illustrating the core withoverlaminate film, as placed in a laminator;

FIG. 8 is an exploded view of a plastic card produced by the process ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a plastic card including at least oneelectronic element embedded therein. The present invention also relatesto a hot lamination process for the manufacture of plastic cards, andmore particularly to a hot lamination process for the manufacturer ofplastic cards that include an electronic element, such as a computerchip or other electronic element embedded therein. The electronicelement may perform a wide variety of functions and take a wide varietyof forms. Such cards, without regard to the particular electronicelement embedded therein, will hereinafter be referred to as smartcards. The present invention also relates to a card formed in accordancewith the invention.

In its preferred embodiment and as illustrated in FIGS. 1 and 2, thepresent invention relates to the manufacture of a dual function card, aparticular type of smart card which utilizes a dual functioncontact/contactless microprocessor chip, as described previously herein.However, it will be appreciated by those skilled in the art, that themethod of hot lamination described herein could easily be applied toother identity card or smart card applications.

Referring now to FIGS. 1, 2, and 2A there can be seen a plastic card 10manufactured in accordance with the present invention and including anelectronic element, generally 20, embedded therein. Card 10 includes anupper surface 12 and a lower surface 14. Electronic element 20 may takea wide variety of forms (microprocessor chip, circuit board,transponder, etc.) and perform a wide variety of functions. As shown inFIGS. 2, 2A, and 3A, electronic element 20 may comprise a read/writemicro-chip 22 including a wire antenna 24 connected thereto, any othersuitable electronic element. These electronic elements 20, 22 and 24 andtheir insertion into plastic cards is not new, however, the presentinvention provides a new hot lamination process for manufacturingplastic cards 10 with these electronic elements embedded therein suchthat the cards 10 are of a superior quality, meet all ISO and otherindustry specifications and standards, and are sufficiently smooth andotherwise is capable of receiving dye sublimation printing. Electronicelements such as these described are available from manufacturers suchas Motorola and Philips Electronics.

Upper surface 12 contains a window or cavity 16 formed therein andintended to expose one or more contact pads 26 operatively connected toantenna 24. Upon formation of card 10 in accordance with the preferredembodiment, a microprocessor chip 22 is inserted into window 16 and inelectrical connection with contact pads 26. This microprocessor chip mayfunction as a “proximity” or radio frequency identification (RFID) cardin conjunction with antenna 24 when electromagnetically used with acompatible terminal reader. Microprocessor chip 22 is also capable offunction as a contact card, requiring physical contact between acompatible terminal reader and the surface of chip 22. It should beappreciated that the contact function of the card may be accomplished byany contact sensor whether integral to or physically separate from chip22 and that window 16 may be formed anywhere on surfaces 12 and/or 14 aswill accomplish the purposes of the invention.

Specifically, a card in accordance with the present invention has athickness of approximately in the range of 0.028 inches to 0.032 incheswith a surface smoothness of 0.0005 inches. In order to meet the ISOstandards for such cards, these tolerances apply to the surface of themicroprocessor chip 22 surface as well as to the surface of plasticportion of card 10. It is to be appreciated that cards having athickness greater than 0.032 inches can easily be manufactured inaccordance with the teachings herein while meeting all of the othercriteria of the present invention. However, the foreseen product demandis for cards meeting the aforementioned standards.

As shown in FIG. 4, one or more cards 10 in accordance with the presentinvention may be manufactured by positioning an electronic element 20,including contact points 26, between first and second sheets of cardstock 30, 32 to form a core 33. Preferably as shown, a plurality ofcards are manufactured simultaneously, and accordingly a plurality ofelectronic elements 20 are positioned between the first and secondsheets of plastic core stock 30, 32. When a plurality of electronicelements 20 are positioned between first and second sheets plastic corestock 30, 32, electronic elements 20 are properly positioned relative toone another such that a plurality cards may be cut from the resultingcard stock.

Plastic core sheets 30, 32 may be provided by a wide variety ofplastics, the preferred being polyvinyl chloride (PVC) having athickness in the range of 0.007 inches to 0.024 inches and preferablyhaving a thickness of approximately 0.0125 inches each. Those skilled inthe art will recognize that the thickness of the plastic core sheetswill depend somewhat upon the thickness of the one or more electronicelements that are to be embedded therebetween if ISO standards areintended to be met. Other suitable plastics that may be utilized includepolyester, acrylonitrile-butadiene-styrene (ABS), and any other suitableplastic.

Subsequent to placing one or more electronic elements 20 between thefirst and second sheets 30, 32 of plastic core stock to form a core 33,this core 33 is placed in a laminator apparatus 40 of the type wellknown in the art of plastic card manufacturing. As is shown in FIG. 5,laminator 40 includes upper and lower platens 42,44 for applying rampressure to an article positioned therebetween. In addition to theability to apply ram pressure, laminator 40 is preferably of the typehaving controlled platens 42,44 that may provide both heat and chillcycles and preferably includes cycle timer to regulate cycle time. Core33 is positioned between first and second laminating plates 50, 52, oneof which is preferably matte finished to provide laminated core 33 withat least one textured outer surface. First and second laminating pads60, 62 are positioned outside of the laminating plates 50, 52, and firstand second steel plates 70, 72 are likewise positioned outside of padsof 60, 62 and the entire assembly forms a book 37 for being positionedin laminator 40 between platens 42, 44.

Once book 37 is positioned in laminator 40 as shown in FIG. 5, the firstlamination cycle is initiated by closing laminator platens 42, 44,preferably applying little or no ram pressure to book 37. This ispreferably done using hydraulic pressure, and a pressure not to exceedabout 10 pounds per square inch is believed sufficient for mostapplications.

A laminator heat cycle is initiated, bringing the temperature of platens42,44 up to a range of 275° F. to 400° F., and most preferably up to arange of 300° F. to 370° F. for a period of ranging between 1 to 20minutes, but preferably greater than 5 minutes, and most preferably inthe range of 7 to 10 minutes for PVC material. It must be understoodthat the temperatures recited herein are by means of example. The use ofthermoplastic material other than PVC or the presence of pigments in thecore material may require modification of the heat cycle temperature.

Once the heat cycle has been applied to book 37 as is set forth above,the ram pressure of laminator 40 is increased to facilitate the flow ofthe plastic core sheets 30, 32 so that the one or more electronicelements 20 become encapsulated thereby, and so that sheets 30, 32 forma uniform core 33 with upper and lower surfaces 34,35. The ram pressuretranslates into an effective pressure on core 33 in the range of 200 to450 psi and preferably in the range of 250 to 350 psi. As can beexpected temperature and pressure are inversely related to one another.In other words a lamination cycle at a higher temperature will requireless pressure to be applied to core 33, and conversely a lowertemperature heat cycle will require increased ram pressure. Damage tothe electronic components can result from excessive ram pressure on thecore while insufficient ram pressure will likely cause an inadequateflow of the plastic resulting in air pockets or an irregular cardsurface.

As mentioned, the use of matte finished laminator plates 50,52 providessurfaces 34, 37 with a slightly roughened or textured quality which willfacilitate the application of a coating thereto as is discussed below.The ram pressure applied during the heat cycle and the length of theheat cycle may vary, depending especially upon the size of sheets 30,32. For example, the cycle time may be in the range of 10-15 minutes. Inone example, at a temperature of approximately 320 degrees Fahrenheit, aram pressure of 940.135 pounds per square inch (p.s.i.), producing apressure of about 275 psi at the core 33 surface, was applied for 10-15minutes to form a uniform core 33, using sheets 30,32 of a size in therange of 12 inches by 24 inches to 24 inches by 36 inches.

Subsequent to the above heat cycle, laminator 40 applies a chill cycleto book 35 during which time the ram pressure of the laminator 40 isincreased, preferably by approximately 10-40% and most preferably about25% until the platens 42,44 have cooled so as to return the corematerial to a solid state. In the preferred method the platens 42, 44are cooled to approximately 40° F. to 65° F. for approximately 10-15minutes. Core 33 may then be removed from laminator 40 for additionalprocessing.

Subsequent to the removal of core 33 from laminator 40, and asillustrated in FIG. 6, core 33 is coated on at least one of its upperand lower surfaces 34, 35 with a layer of printing ink 36. This may beaccomplished using a wide variety of printing techniques such as offsetprinting, letterpress printing, screen printing, roller coating, sprayprinting, litho-printing, and other suitable printing techniques. Asshown in FIG. 6, core 33 is fed in the direction indicated with arrow Athrough a printing press, a lithographic printer, or a similar apparatus80. This printing step is performed to coat at least one surface 34, 35of core 33 with a layer of aesthetically pleasing ink 36. This layer ofink 36 can also serve to cosmetically hide the one or more electronicelements 20 that are embedded within core 33, and prevent these one ormore electronic elements 20 from showing through the relatively thincore 33. In this manner, the one or more electronic elements 20encapsulated in core 33 are completely hidden from view withoutrequiring the plastic used in the manufacture core 33 to be excessivelythick (exceeding ISO standards for cards of this type).

Referring now to FIG. 7, the final preferred, but optional processing ofcore 33, which now comprises a layer of ink 36 or the like on at leastone surface 34, 35 thereof, is schematically illustrated. Anoverlaminate layer such as clear overlaminate film 38 is positioned onat least one ink coated surface 34, 35 of core 33, and preferably core33 is positioned between two similar sheets of overlaminate film 38,39as shown. Overlaminate film is very thin, for example in the range of0.0015″ thick. A book 135 is then constructed for insertion intolaminator 40 as is schematically illustrated in FIG. 7. Book 135comprising core 33, including at least one layer of ink 36 and at leastone layer of overlaminate film 38, 39 is positioned between laminatingplates which are preferably highly polished plates such as mirrorfinished stainless steel plates 91, 92. Book 135 also comprises firstand second laminating pads 60, 62 and first and second steel plates 70,72 as is discussed above in relation to FIG. 7.

When book 135 is positioned between upper and lower platens 42, 44 oflaminator 40 as shown in FIG. 7, the laminator is closed and a heatcycle in the range of 175° F. to 300° F., and most preferably in therange of 180° F. to 275° F., is applied to book 135 for a period of 10to 25 minutes to produce a pressure on book 135 of between 200 to 450psi, preferably 250-350 psi, with a ram pressure that varies dependingupon sheet size or the ram size of the laminator 40, but which istypically approximately 1000 p.s.i. with an 18 inch diameter ram. Thisstep causes the overlaminate layer 38 to flow in order to produce auniform protective layer over the printing.

The laminator 40 is then caused to execute a chill cycle, preferablywith a corresponding increase in ram pressure. For example, the chilltemperature may be in the range of 40° F. to 65° F. and last for aperiod of 10 to 25 minutes. However, any combination of temperature andtime which permits the re-solidification of the overlaminate layer 38may be used. A ram pressure increase of approximately 10 to 40% over thepressure used for the heat cycle has been found to be preferable, with apressure increase of approximately 25% being most desirable.

It is important to note that the use of pressure, or more significantlytemperature, in the second lamination cycle should only affect theoverlaminate layer 38 and should not cause softening or re-flow ofplastic core 33. In lieu, of this preferred overlamination process, itis to be understood that colorfast inks may not require an overlaminatelayer or that alternative overlaminates such as those applied by spray,silk screening or roll on may be used.

Subsequent to the above described second lamination cycle, a sheet ofplastic card stock is provided which comprises at least core 33 with atleast one surface 34, 35 thereof covered by a layer of ink 36, and withat least one surface 34,35 thereof covered by a layer of overlaminatefilm 38, 39.

Preferably plastic card stock manufactured in accordance with thepresent invention comprises core 33 covered on both surfaces 34, 35 witha layer of ink 36 which is positioned between layers of overlaminatefilm 38, 39, all of which has been laminated together as described andas shown in FIG. 8. One or more cards 10 then may be cut from theresulting plastic card stock and card 10 will have a thickness in therange of 0.028 inches to 0.032 inches with variation in overallthickness across the surfaces 12, 14 thereof being no greater thanapproximately 0.0005 inches. The one or more cards 10 can thus be saidto have a glossy surface smoothness of approximately 0.0005 inches orbetter. Thus, a card 10 manufactured in accordance with the presentinvention includes at least one surface 12, 14 at preferably bothsurfaces 12,14 that are sufficiently smooth, glossy and regular toreceive dye sublimation printing.

In the preferred embodiment, each card 10 undergoes a controlled-depthmilling operation to form a window or cavity 16 and to expose one ormore of the contact pads 26 connected to the antenna 24. Thereafter, amicroprocessor chip 22 having a contact surface is inserted into thecavity and in electronic contact with contact pads 26. Chip 22 may beattached to contact pads 26 by known means such as conductive adhesives(including those cured by UV or sonic energy) or low temperature solder.The overall thickness of the card including the area occupied by chip 22meets ISO standards and is capable of operation in compatible physicalreaders.

In an alternative embodiment, a cavity or window 16 is formed in thefirst or second sheet of plastic core stock, prior to the firstlamination step. The core stock is positioned over the electronicelement, generally 20, to expose one or more contact pads 26. This mayalso be done using electronic elements wherein microprocessor chip 22 isalready attached to contact pads 26 and/or antenna 24 in which case thecavity is positioned over and around chip 22. As shown in FIG. 5a, aspacer 90 is inserted into cavity 16 and over contact pads 26 or chip22. The spacer 90 may be integral to one of the matte laminating plates50, 52 or separate therefrom and made of any suitable non-stick materialsuch as Teflon®. Spacer 90 is utilized to prevent or limit the flow ofplastic into cavity 16 during the lamination process so as not to covercontact pads 26 or chip 22 with plastic. When spacer 90 is non-integralwith matte laminating plate 50 or 52 it may be removed or cut-away aftereither the lamination or overlamination process to expose cavity 16 andallow microchip 22 to be inserted therein and retained by such means asare known in the art, including solder or adhesives. In this embodimentwhere the chip is installed prior to lamination, when viewed incross-section the outer surface of chip 22 is below the upper surface 34or core sheet 35 prior to lamination, thus core sheets will accept themajority of applied pressure from the laminator. Spacer 90 providesfurther protection. As the core material softens, the plastic will flowaround spacer 90 and chip 22 and the distance between the outer surfaceof chip 22 and the upper surface of core sheet 35 will decrease.

Those skilled in the art will recognize that the foregoing descriptionhas set forth the preferred embodiment of the invention in particulardetail and it must be understood that numerous modifications,substitutions, and changes may be undertaken without departing from thetrue spirit and scope of the present invention as defined by the ensuingclaims. For example, it should be understood that the methods asdescribed can be performed with or without the printing or coating stepsand still fall within the scope of the invention.

What is claimed is:
 1. A process for incorporating at least oneelectronic element in the manufacture of a plastic card, comprising thesteps of: (a) providing first and second plastic core sheets: (b)positioning said at least one electronic element in the absence of anon-electronic carrier directly between said first and second plasticcore sheets to form a core, said plastic core sheets defining a pair ofinner and outer surfaces of said core; (c) positioning said core in alaminator apparatus, and subjecting said core to a heat and pressurecycle, said heat and pressure cycle comprising the steps of: (i) heatingsaid core for a first period of time; (ii) applying a first pressure tosaid core for a second period of time such that said at least oneelectronic element is encapsulated by said core; (iii) cooling said corewhile applying a second pressure to said core, the second pressure beingat least 10% greater than the first pressure; and (d) milling a regionof said core to a controlled depth so as to form a cavity which exposesat least one contact pad of said at least one electronic element.
 2. Theprocess for incorporating at least one electronic element in themanufacture of a plastic card as recited in claim 1, wherein saidlaminator apparatus has first and second laminating plates, at least oneof said first and second laminating plates having a matte finish forcreating a textured surface on at least one of said outer surfaces ofsaid core.
 3. The process for incorporating at least one electronicelement in the manufacture of a plastic card as recited in claim 2,wherein each of said first and second laminating plates has a mattefinish for creating said textured surface on both of said outer surfacesof said core.
 4. The process for incorporating at least one electronicelement in the manufacture of a plastic card as recited in claim 1,wherein said first and second plastic core sheets are made from amaterial selected from the group consisting of polyvinyl chloride,polyester, and acrylonitrile-butadiene-styrene, each of said sheetshaving a thickness in the range of 0.007 to 0.024 inch.
 5. The processfor incorporating at least one electronic element in the manufacture ofa plastic card as recited in claim 4, wherein said first and secondplastic core sheets have a thickness of approximately 0.0125 inch. 6.The process for incorporating at least one electronic element in themanufacture of a plastic card as recited in claim 1, wherein said secondpressure ranges from about 10% to about 40% greater than said firstpressure.
 7. A process as recited in claim 1 having a further stepfollowing step(c), said step comprising: positioning a layer ofoverlaminate film on at least one of said surfaces of said core,positioning said overlaminate film and said core in a laminatorapparatus and laminating said layer of overlaminate film to said core insaid laminator to thereby form a sheet of plastic card stock.
 8. Theprocess of claim 7, further comprising the step of coating said at leastone surface of said core with a layer of ink prior to positioning saidoverlaminate film on said at least one surface of said core.
 9. Theprocess for incorporating at least one electronic element in themanufacture of a plastic card as recited in claim 1, wherein said coreis heated in step (c)(i) to a temperature in the range of 275° F. to400° F. and said first period of time is at least five (5) minutes. 10.The process for incorporating at least one electronic element in themanufacture of a plastic card as recited in claim 1, wherein said firstpressure is approximately 450 p.s.i. and said second period of time isat least 10 minutes.
 11. The process for incorporating at least oneelectronic element in the manufacture of a plastic card as recited inclaim 1, wherein a coating step is carried out on at least one surfaceof said core utilizing a printing press.
 12. The process forincorporating at least one electronic element in the manufacture of aplastic card as recited in claim 1, wherein a coating step is carriedout on at least one surface of said core utilizing a coating techniqueselected from the group consisting of silk screen printing, offsetprinting, letterpress printing, screen printing, roller coating, sprayprinting, and litho-printing.
 13. The process for incorporating at leastone electronic element in the manufacture of a plastic card as recitedin claim 1, having a further step after said step (c) comprising: (a)positioning an overlaminate film on said at least one surface of saidcore; (b) subjecting said core to a heat and pressure cycle comprisingthe steps of: (i) heating said core to a temperature betweenapproximately 175° F. to 300° F. for approximately 10 to 25 minutes;(ii) applying approximately 1000 p.s.i. pressure to said core; and (iii)cooling said core to a temperature in the range of approximately 40° F.to 65° F. for approximately 10 to 25 minutes.
 14. The process of claim13, further comprising the step of coating said at least one surface ofsaid core with a layer of ink prior to positioning said overlaminatefilm on said at least one surface of said core.
 15. A process as recitedin claim 1 comprising the further step of inserting a second electronicelement into said cavity, the second electronic element being inelectrical communication with the at least one electronic element. 16.The process for incorporating at least one electronic element in themanufacture of a plastic card as recited in claim 1, wherein said atleast one electronic element is a micro-chip and an associated circuitboard antenna or an associated wire antenna.
 17. The process forincorporating at least one electronic element in the manufacture of aplastic card as recited in claim 1, wherein said at least one electronicelement is a read/write integrated chip and an associated antenna. 18.The process according to claim 1, wherein the pressure on said core instep (c)(i) is less than 10 p.s.i.
 19. The process according to claim 1,wherein said core is heated in step (c)(ii).
 20. A process forincorporating at least one electronic element in the manufacture of aplastic card, comprising the steps of: (a) providing first and secondplastic core sheets; (b) positioning said at least one electronicelement in the absence of a non-electronic carrier directly between saidfirst and second plastic core sheets to form a core, said plastic coresheets defining a pair of inner and outer surfaces of said core; (c)positioning said core in a laminator apparatus, and subjecting said coreto a heat and pressure cycle, said heat and pressure cycle comprisingthe steps of: (i) heating said core for a first period of time; (ii)applying a first pressure to said core for a second period of time suchthat said at least one electronic element is encapsulated by said core:(iii) cooling said core while applying a second pressure to said core,the second pressure being at least 10% greater than the first pressure.21. The process according to claims 20, further comprising: forming acavity in said core.
 22. The process according to claim 21, wherein thestep of forming a cavity in said core comprises: after step (c), millinga region of said core to a controlled depth so as to form a cavity whichexposes at least one contact pad of said at least one electronicelement.
 23. The process according to claim 22, further comprising:inserting a second electronic element into said cavity, the secondelectronic element being in electrical communication with the at leastone electronic element.